assembly.
WARNING: Wear eye/face protection when using compressed air and cleaning
fluids.
CAUTION: Regulate air pressure up to a maximum of 75 PSI.

1. Confirm the CVT case is on the work
bench with sub-assembly side down.


Use wood blocks as necessary to
stabilize the assembly during these
steps.

CAUTION: Make sure the surface of the
work bench has been cleaned.

Figure 1L

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2. Spray brake cleaner into each oil passage, indicated in yellow, of the CVT case where
shown in Figure 2L and Figure 3L, until the fluid runs clear for 5 seconds.
IMPORTANT: Do not apply brake cleaner or compressed air to passages circled in
white.
3. Apply compressed air in the same passages to remove remaining cleaner and debris.
NOTE: Do not stand in front of the passages while using compressed air.

Figure 2L

Figure 3L

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4. Spray brake cleaner into the reverse
brake tube.


Apply compressed air in the same
passages to remove remaining
cleaner and debris.
Reverse brake
tube

Figure 4L

5. Clean the input shaft bearing bore area (Figure 5L).
Input shaft
bearing bore

Figure 5L

6. Spray brake cleaner into the high clutch
fluid passage on the torque converter
housing.

High clutch fluid
passage

CAUTION: Brake cleaner will exit the
passage shown as “fluid discharge” in
Figure 6L while cleaning passage.


Apply compressed air in the same
passages to remove remaining
cleaner and debris.
Fluid discharge
Figure 6L

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7. Spray brake cleaner into the reduction
gear bearing fluid passage on the torque
converter housing.

Reduction
gear bearing
fluid passage

CAUTION: Do not face the passage
indicated in red of Figure 7L while
cleaning.


Apply compressed air in the same
passages to remove remaining
cleaner and debris.
Fluid discharge
Figure 7L

8. Clean the passages of the oil pump cover
as follows:

Input shaft

Oil pump cover

a. Remove the input shaft from the oil
pump cover.
CAUTION: Do not drop the counter
bearing outer race (roller bearing type
only).

Figure 8L

b. Note the orientation and then remove
the thrust bearing.


Thrust bearing

Do NOT discard. This will be
reused at a later step.

Figure 9L

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c. Remove the washer.


Washer

Do NOT discard. This will be
reused at a later step.

d. Spray brake cleaner into the oil pump
cover oil passages indicated in yellow
shown in Figure 11L.


Apply compressed air in the same
passages to remove remaining
cleaner and debris.
Figure 10L

CAUTION: Do not face the passage indicated in white in Figures 11L and 12L while
cleaning.
Oil pump cover

Oil pump cover

Fluid discharge
Figure 11L

Figure 12L

e. Install the original washer.
Washer

NOTE:


Orientation is NOT critical for
the washer.



Apply petroleum jelly to the
washer to hold it in place
during assembly.

Figure 13L

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f. Install the original thrust bearing.


Orientation IS critical. See Figure 14L and Figure 15L for thrust bearing cross
section.

CAUTION:



The thrust bearing has two sides. Refer to Figures below.
Apply petroleum jelly or equivalent to hold in place.

Oil pump cover

Thrust bearing

Figure 14L

Figure 15L

g. Insert the input shaft to the oil pump cover (Figure 16L).
CAUTION:




The input shaft has a sealing ring.
Be careful not to damage the sealing ring while assembling the input shaft to
the oil pump cover.
Apply petroleum jelly to the sealing ring on the input shaft before installation.
 Sealing ring is hidden behind input gear in Figure 16L.
Oil pump cover
Thrust bearing

Sealing ring location
Figure 16L

Figure 17L

 Make sure all exposed internal areas of the CVT (including the oil pan and magnets)
have been thoroughly cleaned.
 Cover all parts with a lint-free covering, when not being worked on, to prevent
contamination which could cause drivability concerns.
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Measuring the CVT Sub-assembly Case Depth

Torque converter
housing
1. Temporarily install the torque converter
housing to the CVT case with two (2)
bolts at opposite corners, hand tight
(Figure 1M).


Use original bolts to secure.

Figure 1M

2. Reposition the CVT on the work bench
with the torque converter housing side
facing down (Figure 2M).
3. Clean and then zero the Digital Depth
Gauge (J-50272).

4. Set the Digital Gauge to millimeters.

Figure 2M
5. Clean the Gauge Block (J-50271).
NOTE: Only if a Gauge Block (J-50271)
is not available, measurement “X” (Figure
5M, page 60) will need to be determined
for the measuring bar being used. This
can be done either with a set of calipers
or with Digital Depth Gauge (J-50272).

Gauge Block
(J-50271)

6. Confirm the sealing surfaces of the CVT
case are clean.
7. Place Gauge Block (J-50271) across
sub-assembly sealing surface as shown
in Figure 3M.
Figure 3M

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8. Measure the average distance (Y) shown in Figure 5M as follows:


Refer to the Figures 4M and 5M and then proceed to page 61.



Measure only from areas that do not have any signs of contact.
IMPORTANT: Please refer to Figure 4M for acceptable areas (highlighted in green)
to measure “Y”.
Measuring area

Do not measure in this
area
Figure 4M

Y = The distance between the upper surface of the Gauge Block and the surface where
snap ring seats.

Figure 5M

Proceed to the next page.

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Secondary pulley bearing snap ring surface
Do not measure
into this groove.

Measure to this slightly
raised machined surface
Figure 6M
a. Measure between the top of the Gauge Block (J-50271), to where the snap ring on
the secondary pulley bearing seats (Figure 6M).


This will be measured in three locations to calculate an average for “Y”.

Y1_________, Y2________, Y3_________
b. Calculate the average for “Y” with the formula below and then record it below.

Y=

(millimeter)

Y = _________
c. Calculate case depth “D” as follows:
IMPORTANT: Essential tool Gauge Block (J-50271) is 20 mm thick.


Average depth calculated in step 8b →



Subtract Gauge Block thickness

→

Y__________
─ X__________
-------------------------------------------------



→

Calculated depth

= D__________

D = Distance between the sub-assembly sealing surface and the secondary pulley
front bearing surface with the snap ring attached.
EXAMPLE:
If
Y = 61.39 mm
And ─ X = 20.00 mm
___________

D = 41.39 mm
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New Snap Ring Selection and Installation to the New Sub-assembly

1. Remove the top of the shipping box of
the new sub-assembly.

Top of the
shipping box

NOTE: The outer cardboard of the
shipping box can be disassembled for
easy removal of the sub-assembly by
removing the shipping tape.

Figure 1N

2. Remove the upper board with foam
spacer assembly.


Packing material may be different
then what is shown in Figure 2N.
Upper board

Figure 2N
3. Locate the data sheet in the shipping box
and place it in a safe place.


This data sheet is required for snap
ring selection in the following steps.

Figure 3N

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4. Locate the plastic bag which contains the
snap rings (Figure 4N).


There are six individual snap rings in
the plastic bag.



Take the plastic bag out of the
shipping box, and put aside on the
work bench.

NOTE: See Reference # 5 in the KIT
PARTS REFERENCE TABLE.

Snap ring set
Figure 4N

5. Take the new sub-assembly out of the
shipping box and place it on the work
bench.
CAUTION:


Hold the sub-assembly by the side
cover ONLY when removing it
from the shipping box.



DO NOT handle the belt or pulleys
of the sub-assembly when
removing from the shipping box.



DO NOT BREAK the foam cushion
in the shipping box. This will be
used as a stabilizer for the subassembly during the repair.

New sub-assembly
Figure 5N

NOTE: See Reference # 4 in the KIT
PARTS REFERENCE TABLE.

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6. Take the lower board with foam cushion (lower board) out of the shipping box (shown in
Figure 7N).
IMPORTANT: Step 7 is for kits that have a
separate spacer (Figure 6N). In later kits
this spacer will be part of the lower board
and step 7 will not be used.
7. Take the spacer (Figure 6N) out of the
shipping box and place on the work
bench where the sub-assembly will be
installed, and then place the lower board
on top of the spacer as shown in Figure
7N.
NOTE: The spacer will be the last item
that is removed from the shipping box
and is approximately 1 inch thick.

Spacer

Figure 6N



Position the lower board so that it hangs over the spacer.



Align the lower board so that the left and right cut outs are even with the spacer.

NOTE: The positioning of the lower board with foam cushion will allow the CVT case
enough clearance from the work bench to allow it to seat flush with the sub-assembly.
Cut out even
with spacer

Lower board with
foam cushion

Lower board
over-hang

Cut out even
with spacer

Cut out even
with spacer
Figure 7N

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8. Remove the sub-assembly from the
plastic bag.

9. Place the new sub-assembly onto the
lower board.


The sub-assembly must be level and
oriented as shown in Figure 8N for
proper seating of the CVT case later
in this procedure.
Lower board
and spacer

10. Remove the snap ring from the
secondary pulley front bearing of the new
sub-assembly.


Figure 8N

New sub-assembly

Discard the removed snap ring.

Snap ring
Figure 9N

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11. Calculate “E” for snap ring selection as follows:

NOTE: For the value of “B1”, refer to the data sheet that was put aside when the subassembly shipping box was opened.


Calculated case depth from step 8c on page 62

→

D ___________



Subtract constant value

→

─
41.30
------------------------------------



Subtotal